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ESX 4.1 (boot from USB) to vSphere 5.0 U3

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I am in the process of attempting to upgrade some IBM x3850 hosts from vSphere 4.1 to vSphere 5.0 Update 3. The hosts all boot from an internal 4GB USB drive.

 

I successfully upgraded vcenter and Update Manager to version 5.0u3 , I then imported the ESXi 5.0u3 iso into Update Manager, created a basline, attached to my 1st host. Went through the remediation process, and started the upgrade. After 30-40 mins the host still hadn't come back online, so I attached a KVM to the hosts and we greeted with the following screenshot

 

Partition-Error.jpg

 

I reboot the server, and let it go through the upgrade process again. The same error occurs, I try a 3rd reboot and the server gives me the 'No Operating System found. In the end I have to install from scratch.

 

Has anyone come across this issue or any gotchas when attempting to upgrade a server which boots from USB?


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